FSI-Simulation of Liquid Supported Stretch Blow Molding (LBO): Model Validation and Study of Series Production Scenario

Abstract:

Liquid-Driven Stretch Blow Molding is a new and innovative method to produce PET bottles [. In the well-established Stretch Blow Molding (SBM) process, preforms are biaxially deformed by pressurized air into a cavity. The resulting bottles are transferred to a separate machine, where the desired product is filled in. In contrast to that, Liquid-Driven Stretch Blow Molding is characterized by employing the liquid product to deform the material. The former separated blowing and filling steps are thus combined to a single forming stage leading to numerous advantages in energy consumption, cycle time and machine footprint. In this paper, a numerical simulation of the new process is presented. An additional challenge compared to SBM simulations is thereby the consideration of the interaction between liquid and preform. The load application cannot be solely represented by the pressure because the influx behavior as well as gravity and inertia forces influence the preform deformation. A smoothed particle hydrodynamics (SPH) approach is applied to the simulation to incorporate the additional effects. The process model is evaluated by prototype experiments. In addition, a feasibility study shows the applicability of a rotary forming system to the new process.

• Periodical: Key Engineering Materials (Volumes 611-612)
• Pages: 892-900
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.611-612.892
• Online since: May 2014
• Authors: Johannes Zimmer, Markus Stommel
• Keywords: Fluid Structure Interaction (FSI), Smoothed Particle Hydrodynamic (SPH), Stretch Blow Molding

References

[1] Desanaux, C., Contal, A., and Denis, G., Method of producing a polyester resin container and device for performing the same, EP 1 507 642 B1, E. P. Office, (2003).

[2] Denis, G., and Contal, A., Process of manufacturing containers made of polyester resin, EP 1 529 620 B1, E. P. Office, (2003).

[3] Li, H. X., and Buckley, C. P.: Evolution of strain localization in glassy polymers: A numerical study, International Journal of Solids and Structures 46 (2009) 1607-1623.

DOI: 10.1016/j.ijsolstr.2008.12.002

[4] Luo, Y. M., Chevalier, L., and Monteiro, E.: Identification of a Visco‐Elastic Model for PET Near Tg Based on Uni and Biaxial Results, AIP Conference Proceedings 1353 (2011) 750-755.

DOI: 10.1063/1.3589605

[5] Billon, N., Picard, M., and Gorlier, E.: Stretch blow moulding of PET; structure development and constitutive model, International Journal of Material Forming (2013) 1-10.

DOI: 10.1007/s12289-013-1131-1

[6] Menary, G. H., Tan, C. W., Armstrong, C. G. et al.: Validating Injection Stretch-Blow Molding Simulation Through Free Blow Trials, Polymer Engineering and Science 50 (2010) 1047-1057.

DOI: 10.1002/pen.21555

[7] Bordival, M., Schmidt, F. M., Le Maoult, Y. et al., Simulation of the Two Stages Stretch-Blow Molding Process: Infrared Heating and Blowing Modeling, AIP Conference Proceedings, American Institute of Physics, 2007, pp.519-524.

DOI: 10.1063/1.2740863

[8] McEvoy, J. P., Armstrong, C. G., and Crawford, R. J.: Simulation of the stretch blow molding process of PET bottles, Advances in Polymer Technology 17 (1998) 339-352.

DOI: 10.1002/(sici)1098-2329(199824)17:4<339::aid-adv5>3.0.co;2-s

[9] Wang, S., Makinouchi, A., and Nakagawa, T.: Three-dimensional viscoplastic FEM simulation of a stretch blow molding process, Advances in Polymer Technology 17 (1998) 189-202.

DOI: 10.1002/(sici)1098-2329(199823)17:3<189::aid-adv1>3.0.co;2-o

[10] Menary, G. H., Tan, C. W., Picard, M. et al.: Numerical Simulation of Injection Stretch Blow Moulding: Comparison with Experimental Free Blow Trials, AIP Conference Proceedings 907 (2007) 939-944.

DOI: 10.1063/1.2729634

[11] Brandau, O.: Stretch Blow Molding. William Andrew, (2012).

[12] Gingold, R. A., and Monaghan, J. J.: Smoothed particle hydrodynamics - Theory and application to non-spherical stars, Monthly Notices of the Royal Astronomical Society 181 (1977) 375-389.

DOI: 10.1093/mnras/181.3.375

[13] Birnbaum, N. K., Francis, N. J., and Gerber, B. I.: Coupled techniques for the simulation of fluid-structure and impact problems, Computer Assisted Methods in Engineering and Science 6 (1999) 295-311.

[14] Molteni, D., and Colagrossi, A.: A simple procedure to improve the pressure evaluation in hydrodynamic context using the SPH, Computer Physics Communications 180 (2009) 861-872.

DOI: 10.1016/j.cpc.2008.12.004

[15] Monaghan, J. J.: Smoothed particle hydrodynamics, Reports on Progress in Physics 68 (2005) 1703.

[16] Abaqus: Abaqus Analysis User's Manual, Version 6. 12. Dassault Systèmes Simulia Corp., (2012).

[17] Grüneisen, E.: Theorie des festen Zustandes einatomiger Elemente, Annalen der Physik 344 (1912) 257-306.

DOI: 10.1002/andp.19123441202

[18] Shyue, K. -M.: A Fluid-Mixture Type Algorithm for Compressible Multicomponent Flow with Mie–Grüneisen Equation of State, Journal of Computational Physics 171 (2001) 678-707.

DOI: 10.1006/jcph.2001.6801

[19] Jeanloz, R.: Shock wave equation of state and finite strain theory, Journal of Geophysical Research: Solid Earth 94 (1989) 5873-5886.

DOI: 10.1029/jb094ib05p05873

[20] Shukla, A., Ravichandran, G., and Rajapakse, Y.: Dynamic Failure of Materials and Structures. Springer, (2009).

[21] Buckley, C. P., and Jones, D. C.: Glass-Rubber Constitutive Model for Amorphous Polymers near the Glass-Transition, Polymer 36 (1995) 3301-3312.

DOI: 10.1016/0032-3861(95)99429-x

[22] Buckley, C. P., Jones, D. C., and Jones, D. P.: Hot-drawing of poly(ethylene terephthalate) under biaxial stress: application of a three-dimensional glass—rubber constitutive model, Polymer 37 (1996) 2403-2414.

DOI: 10.1016/0032-3861(96)85352-3

[23] Adams, A. M., Buckley, C. P., and Jones, D. P.: Biaxial hot drawing of poly(ethylene terephthalate): measurements and modelling of strain-stiffening, Polymer 41 (2000) 771-786.

DOI: 10.1016/s0032-3861(98)00834-9

[24] Zimmer, J., Detrois, C., and Stommel, M.: Evaluation Method for Stretch Blow Moulding Simulations with Process-Oriented Experiments, Key Engineering Materials 554-557 (2013) 1658-1668.

DOI: 10.4028/www.scientific.net/kem.554-557.1658

[25] Venkateswaran, G., Cameron, M. R., and Jabarin, S. A.: Effects of temperature profiles through preform thickness on the properties of reheat-blown PET containers, Advances in Polymer Technology 17 (1998) 237-249.

DOI: 10.1002/(sici)1098-2329(199823)17:3<237::aid-adv4>3.0.co;2-t

[26] Shelby, M. D., Horton, K. D., and Hall, H. P., Method and Device for Predicting Temperature Profiles Throughout the Thickness of a Polymer Preform, US 20040024560A1, (2004).